Systems and methods for mounting roof-mounted photovoltaic arrays including flashing and adhesive pads

ABSTRACT

A system for flashing a mount of a photovoltaic assembly on a surface includes a flashing with a lower surface and an upper surface. The flashing defines an opening to receive a fastener for securing the mount to the surface. The system also includes a seal extending around the fastener when the fastener is positioned in the opening. The seal provides a first barrier to inhibit water intrusion through the opening. The system further includes a pad attached to one of the lower surface and the upper surface, wherein the pad provides a second barrier to inhibit water intrusion through an interface of the flashing and the surface.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional patent application of U.S. patentapplication Ser. No. 15/829,274, filed on Dec. 1, 2017, which claimspriority to U.S. Provisional Application No. 62/434,327, filed Dec. 14,2016, the disclosures of which are hereby incorporated by reference intheir entirety for all purposes.

FIELD

This disclosure generally relates to flashing mounting systems for roofsand, more specifically, to flashing mounting systems for roof-mountedphotovoltaic arrays.

BACKGROUND

Photovoltaic (PV) modules may be mounted to a surface of a structuresuch as a roof to form PV arrays. Each PV module may be mounted to thesurface by mounts that secure the PV module to the surface and elevatethe PV module above the surface. Sometimes, securing each mount to thesurface causes one or more penetrations in the surface. Typically,photovoltaic arrays require numerous mounts and, thus, numerouspenetrations in the surface. However, such penetrations may need to besealed to prevent water intrusion into the structure through thepenetrations. For example, flashing may be positioned on the mounts andthe surface may be sealed using sealant materials. Sometimes, seals suchas grommets may be used to seal openings in the flashing. However, thegrommets require pressure to inhibit water intrusion through theopenings and may deteriorate over time. Also, seals or barriers may bepositioned to direct water flow away from the opening. However, thewater may travel around the seals or barriers and through a drainagepath towards the opening. In addition, forces such as wind can causewater to move upwards and overcome raised seals or barriers.Accordingly, such seals and barriers may not completely and reliablyprevent water intrusion into the structure through the penetrations.

At least some flashing may be specially designed for use with themounts. For example, some flashings include a raised interface toinhibit water flow into the penetrations. However, the raised interfaceincreases the cost of materials and time required to assemble theflashing and requires the mount to have an increased size. The increasedsize or height of the mount increases the height of the entire PV arrayand increases the space between the PV array and the roof surface whichcan affect the aesthetics of the system. In addition, some flashingsinclude an additional support to accommodate a seal, which furtherincreases the cost to assemble the systems. Also, the flashing mayexperience stresses and deform when the flashing is connected to thesurface.

Accordingly, there is a need for a system that simplifies the process tomount photovoltaic arrays and provides a reliable and robustwater-resistant seal for penetrations.

This Background section is intended to introduce the reader to variousaspects of art that may be related to various aspects of the presentdisclosure, which are described and/or claimed below. This discussion isbelieved to be helpful in providing the reader with backgroundinformation to facilitate a better understanding of the various aspectsof the present disclosure. Accordingly, it should be understood thatthese statements are to be read in this light, and not as admissions ofprior art.

BRIEF DESCRIPTION

In one aspect, a system for flashing a mount of a photovoltaic assemblyon a surface includes a flashing with a lower surface and an uppersurface. The flashing defines an opening to receive a fastener forsecuring the mount to the surface. The system also includes a first padpositioned along and attached to the lower surface and a second padpositioned along and attached to the upper surface. The first pad andthe second pad extend across the opening. The first pad and the secondpad include an adhesive and form a water resistant seal for the opening.

In another aspect, a system for flashing a mount of a photovoltaicassembly on a surface includes a flashing with a lower surface and anupper surface. The flashing defines an opening to receive a fastener forsecuring the mount to the surface. The system also includes a sealextending around the fastener when the fastener is positioned in theopening. The seal provides a first barrier to inhibit water intrusionthrough the opening. The system further includes a pad attached to oneof the lower surface and the upper surface, wherein the pad provides asecond barrier to inhibit water intrusion through an interface of theflashing and the surface.

In yet another aspect, a system for flashing a mount of a photovoltaicassembly on a surface includes a flashing with a lower surface and anupper surface. The flashing defines an opening to receive a fastener forsecuring the mount to the surface. The system also includes a paddisposed on one of the lower surface and the upper surface by adhesive.The pad is compressible and provides a seal to inhibit water intrusionthrough the opening.

In another aspect, a system for flashing a mount of a photovoltaicassembly on a roofing surface includes a flashing with a lower surfaceand an upper surface. The flashing defines an opening to receive afastener for securing the mount to the surface. The system also includesa pad attached to the lower surface by adhesive. The pad is U-shaped andprovides a barrier to inhibit water intrusion between the roofingsurface and the lower surface of the flashing.

Various refinements exist of the features noted in relation to theabove-mentioned aspects. Further features may also be incorporated inthe above-mentioned aspects as well. These refinements and additionalfeatures may exist individually or in any combination. For instance,various features discussed below in relation to any of the illustratedembodiments may be incorporated into any of the above-described aspects,alone or in any combination.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an installed system 100 for mountingphotovoltaic modules and support structures.

FIG. 2 is an exploded perspective view of the system shown in FIG. 1.

FIG. 3 is an exploded perspective view of all components of the systemshown in FIGS. 1 and 2 prior to assembly.

FIG. 4 is a perspective view of the flashing assembly of the systemshown in FIGS. 1-3.

FIG. 5 is an exploded view of the flashing assembly shown in FIG. 4.

FIG. 6 is a sectional view of a system for mounting photovoltaic (PV)modules on a surface of a structure.

FIG. 7 is a perspective view of an embodiment of a system includingflashing with notches.

FIG. 8 is a perspective view of an embodiment of a flashing assembly anda mount.

FIG. 9 is a perspective view of an embodiment of a system includingflashing with a raised interface for receiving a mount.

FIG. 10 is an exploded view of the system shown in FIG. 9.

FIG. 11 is a side view of the system shown in FIG. 9.

FIG. 12 is a perspective view of an embodiment of a system including aflashing assembly including a water deflection device.

FIG. 13 is a perspective view of an embodiment of a flashing assemblybeing used with a mount in a “direct-to-deck attachment” configuration.

FIG. 14 is an exploded view of the flashing assembly shown in FIG. 13.

FIG. 15 is a perspective view of the flashing assembly shown in FIGS. 13and 14 being used with a mount in a “rafter attachment” configuration.

FIG. 16 is an exploded view of an embodiment of a system includingflashing having an elevated opening.

FIG. 17 is an exploded view of an embodiment of a system including a padand a grommet, the pad including an opening.

FIG. 18 is a perspective view of an underside of the flashing assemblyshown in FIG. 17.

FIG. 19 is an exploded view of an embodiment of a system including afirst pad on a lower surface of a flashing and a second pad on an uppersurface of the flashing.

FIG. 20 is a top view of a flashing assembly with a pull-tab.

FIG. 21 is a partially exploded perspective view of the flashingassembly shown in FIG. 20.

FIG. 22 is a fully exploded perspective view of the flashing assemblyshown in FIGS. 20 and 21.

FIG. 23 is a top view of a flashing assembly with an oversized releasesheet.

FIG. 24 is a partially exploded perspective view of the flashingassembly shown in FIG. 23.

FIG. 25 is a fully exploded perspective view of the flashing assemblyshown FIGS. 23 and 24.

FIG. 26 is a perspective view of flashing assemblies.

FIG. 27 is a perspective view of the flashing assemblies shown in FIG.26 in a stacked arrangement.

FIG. 28 is a perspective view of a system including a flashing assemblyincluding a U-shaped adhesive pad.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

FIG. 1 is a perspective view of an as installed system 100 for mountingphotovoltaic modules and support structures. The system 100 includes amount 104, a fastener 110, a sealing washer 150, and a flashing assembly106. FIG. 2 is an exploded perspective view of the system 100 includingthe flashing assembly 106. FIG. 6 is a sectional view of the asinstalled system 100 for mounting photovoltaic (PV) modules andphotovoltaic support structures on a surface 102 of a structure. Thestructure may be, for example, a building having a sloped or flat roofor any other structure suitable for mounting PV modules. In the example,the structure is a roof and includes shingles 115 and supports 117.

FIG. 3 is an exploded perspective view of all the components of thesystem 100 prior to assembly. FIG. 4 shows the perspective view of theflashing assembly 106. FIG. 5 shows an exploded view of the flashingassembly 106. The flashing assembly 106 includes a flashing 108, a firstpad 118, and a second pad 120. A second release sheet 142 may cover asecond attachment surface 124 of the first pad 118 and a fourth releasesheet 146 may cover a fourth attachment surface 128 of the second pad120. The release sheets 142, 146 may be shipped with the flashingassembly 106 to protect the attachment surfaces 124, 128 until theattachment surfaces 124, 128 are exposed during installation of thesystem 100. In addition, the release sheets 142, 146 may prevent thefirst pad 118 and the second pad 120 from sticking to adjacent flashingassemblies 106 when multiple flashing assemblies are packaged together.

In the example, the mount 104 is a bracket. Fasteners 110 are securedthrough the mount 104, the flashing assembly 106, and into the supports117 of the structure. In other embodiments, the system 100 may includeany mount 104 and/or combination of fasteners 110 that enables thesystem 100 to operate as described.

As an example, embodiments of the systems and methods are described inthe context of PV modules. However, the flashing assemblies 106 may beused to flash any penetrations in surfaces. For example, the describedembodiments may be used for penetrations in roofs such as penetrationsfor heating, venting, and air-conditioning systems, plumbing vents,chimneys, mechanical attachments, and any other components requiringpenetrations in roofs. The term “penetration” refers to an opening in asurface.

The flashing assembly 106 may be connected to the mount 104 andpositioned over any openings in the surface 102. As described furtherbelow, the flashing assembly 106 includes one or more sticky pads 118,120 to provide a water-resistant seal for any penetrations in thesurface. The pads 118, 120 are sticky, i.e., the pads 118, 120 attach tosurfaces. As used herein, the term “sticky” refers to a tendency toattach to surfaces. The pads 118, 120 provide a robust seal betweensurfaces and completely seal the penetrations in the surface 102. Incontrast, known systems form a torturous or raised path for the water.The pads 118, 120 provide a seal without requiring the torturous orraised path. In addition, the pads 118, 120 may attach to all surfacesin the system 100 and provide a seal without requiring a constantpressure. As a result, the embodiments decrease the number of parts andthe part complexity required to provide a water-resistant seal. Inaddition, the pads 118, 120 maintain a seal for a longer time thansystems that require pressure to be applied constantly to maintain theseal.

As shown in FIG. 6, when the mount 104 is secured to the surface 102, aPV module 286 may be attached directly to the mount 104. In anotherexample, a rail or support structure 282 may be attached to the mount104 by a fastener 284 and one or more PV modules 286 may be attached toeach rail 282 by a fastener 288. In other embodiments, the PV modules286 may be mounted in any manner that enables the PV module to functionas described. For example, the PV module 286 and/or the rail 282 may bedirectly attached to the mount 104. In addition, each PV module may beattached directly or indirectly to a plurality of mounts 104.

Referring to FIG. 2, the flashing assembly 106 includes flashing 108 andpads 118, 120. The flashing 108 includes a lower surface 112 and anupper surface 114. The flashing 108 may be positioned between layers ofthe surface 102 as shown in FIG. 6. For example, in this embodiment, theflashing 108 extends between shingles 115 of the surface 102 in anoverlapping arrangement. In some embodiments, the pads 118, 120 allowthe flashing 108 to be positioned on the top of surface 102 because thepads 118, 120 provide a water-resistant seal without requiring anoverlap of the surface 102 and the flashing 108. As shown in FIG. 2, theflashing 108 defines an opening 116 to receive a fastener 110 forsecuring the mount 104 to the surface 102.

With reference to FIGS. 2 and 3, a first pad 118 is attached to thelower surface 112 and a second pad 120 is attached to the upper surface114. The first pad 118 and the second pad 120 extend across andcompletely cover the opening 116 on opposite sides of the flashing 108.Moreover, the first pad 118 and the second pad 120 contact each other atthe opening 116 and bond together to form a unitary structure. As aresult, the first pad 118 and the second pad 120 seal the opening 116.Accordingly, the flashing assembly 106 is configured to receivefasteners 110 but does not include any unsealed openings. In contrast,known systems include unsealed holes that receive fasteners and must besealed after installation. In the example, the first pad 118 and thesecond pad 120 form a membrane that must be penetrated by the fastener110 and that automatically forms a seal around the fastener 110 when thefastener 110 is positioned in the opening 116.

In addition, the first pad 118 and the second pad 120 attach to thefastener 110 when the fastener 110 extends through the opening 116. Thefirst pad 118 and the second pad 120 may be pulled into the penetrationin the surface 102 and seal the penetration when the fastener 110 issecured to the surface 102. Accordingly, the first pad 118 and thesecond pad 120 provide a water-resistant seal for the opening 116 andbetween the flashing assembly 106 and the surface 102 and the supports117. Also, the flashing assembly 106 does not require any field appliedsealant to ensure water resistance at the penetration when the mount 104is secured using the fastener 110. In contrast, known systems requiresealant to be field applied to produce a proper water resistantpenetration. In other embodiments, the flashing assembly 106 may includeany pad 118, 120 that enables the flashing assembly 106 to function asdescribed. For example, in some embodiments, one or more pads 118, 120may be positioned on the lower surface 112 and/or the upper surface 114.

The flashing 108 may be any shape and size. In this embodiment, theflashing 108 is a rectangle and is planar. The flashing 108 may includeany materials including, for example and without limitation, metals,polymeric materials, and rubber. In other embodiments, the flashingassembly 106 may include any flashing 108 that enables the flashingassembly 106 to function as described.

The pads 118, 120 allow the opening 116 to be oversized because the pads118, 120 completely seal the opening 116. Specifically, the opening 116may have a diameter that is greater than the diameter of the fastener110. The diameter of the opening 116 may be greater than the diameter ofthe fastener 110 by a percentage of the diameter of the fastener 110 ina range of about 10% to about 1,000%, or about 15% to about 50%. In theexample, the diameter of the opening 116 is at least 20% greater thanthe diameter of the fastener 110. In contrast, current systems includeopenings that are sized to tightly fit the fasteners 110 because anyexcess space must be sealed after the fastener 110 is installed.

Accordingly, in this embodiment, the fastener 110 does not have to bepositioned precisely to fit into the opening 116 and align the fastener110 with the target location on the surface 102. The target location canbe defined by a pilot hole or by some other means. As a result, the timerequired to secure the system 100 and the flashing assembly 106 to thesurface 102 is significantly reduced compared to previous systems wherenear perfect alignment between the opening and the target location wasrequired. Accordingly, the oversized opening 116 allows blindinstallation (i.e., installation without seeing the target location) andreduces the time required to search for a target location. In otherembodiments, the flashing 108 may include any opening 116 that enablesthe flashing assembly 106 to function as described. For example, in someembodiments, the flashing assembly 106 may include more than one opening116 (see, e.g., openings 237 shown in FIG. 14) and the pads 118, 120 mayseal each opening 116. In addition, the opening(s) 116 can be any shapeincluding circles, ovals, slots, rectangles, trapezoids, pentagons,hexagons, and/or shapes including any number of sides and each openingmay receive more than a single fastener.

FIG. 5 is an exploded view of the flashing assembly 106. The flashingassembly 106 includes a first pad 118 and a second pad 120. The firstpad 118 has a first attachment surface 122 and a second attachmentsurface 124 opposite the first attachment surface 122. The second pad120 has a third attachment surface 126 and a fourth attachment surface128 opposite the third attachment surface 126. Accordingly, the firstpad 118 and the second pad 120 are double-sided adhesive pads.

Prior to installation of the flashing assembly 106, the first attachmentsurface 122 may be attached to the lower surface 112 of the flashing 108and the third attachment surface 126 may be attached to the uppersurface 114. Accordingly, the flashing 108 is “sandwiched” between thefirst pad 118 and the second pad 120. To attach the flashing assembly106 to the surface 102 and to the mount 104, the second attachmentsurface 124 may be attached to the surface 102 and the fourth attachmentsurface 128 may be attached to the mount 104. In other embodiments, thefirst pad 118 and the second pad 120 may be attached to the flashing108, the mount 104, and/or the surface 102 in any manner that enablesthe flashing assembly 106 to function as described.

The first pad 118 and the second pad 120 may be a free form adhesivesuch as a sticky putty or a butyl type tape. In the example, the firstpad 118 and the second pad 120 are made entirely of an adhesivematerial. In other embodiments, the pads 118 and 120 may be a rubber,foam, and/or other polymeric material. In other embodiments, adhesivesmay be included on one or both sides of the pads 118, 120. For example,the pads 118, 120 may include an adhesive on the attachment surfaces122, 124, 126, 128 that is configured to attach to the flashing 108, themount 104, and the surface 102 (shown in FIG. 6). In addition, the firstpad 118 may be designed to seal asphalt, asphalt shingles, concretetiles, clay tiles, rubber, modified bitumen roofing underlayments,roofing membranes such as TPO (thermoplastic polyefin), EPDM (ethylenepropylene diene terpolymer), PVC (polyvinyl chloride), and/or any otherroofing surface. In other embodiments, the flashing assembly 106 mayinclude any pad 118, 120 that enables the flashing assembly 106 tofunction as described.

In another embodiment, the first pad 118 and the second pad 120 may notbe attached to the flashing 108 to form the flashing assembly 106 priorto installation of the flashing assembly 106. For example, the first pad118 and the second pad 120 can be shipped with or separately from theflashing 108 and be attached to the flashing 108 during installation ofthe system 100. To prevent the first pad 118 and the second pad 120 fromattaching to materials prior to installation, the first pad 118 and/orthe second pad 120 may be protected by release sheets as shown in FIG.3. For example, the first pad 118 and the second pad 120 may beprotected by a first release sheet 140, a second release sheet 142, athird release sheet 144, and a fourth release sheet 146 (shown in FIG.3). The first release sheet 140 may be positioned on the firstattachment surface 122 and the second release sheet 142 may bepositioned on the second attachment surface 124 of the first pad 118.The third release sheet 144 may be positioned on the third attachmentsurface 126 and the fourth release sheet 146 may be positioned on thefourth attachment surface 128 of the second pad 120. The first releasesheet 140 may be removed from the first attachment surface 122 and thethird release sheet 144 may be removed from the third attachment surface126 to allow the first pad 118 and the second pad 120 to attach to theflashing 108 and form the flashing assembly 106.

In reference to FIG. 5, the second release sheet 142 may remain over thesecond attachment surface 124 to prevent objects attaching to the secondattachment surface 124 prior to installation of the flashing assembly106. The fourth release sheet 146 may remain over the fourth attachmentsurface 128 to prevent objects attaching to the fourth attachmentsurface 128 prior to installation of the flashing assembly 106. In thisembodiment, each release sheet 140, 142, 144, 146 may comprise a plasticor non-adhesive sheet that covers the attachment surfaces 122, 124, 126,128. In some embodiments, the release sheets 142, 146 may include a gripor tab to facilitate removal of the release sheets 142, 146 as shown inFIG. 20.

FIG. 20 is a top view of the flashing assembly 106 with a pull-tab 262.As shown in FIGS. 21 and 22, the pull-tab 262 includes an adhesivesurface 266 that sticks to the top or the exposed surface of the releasesheets 142, 146 and a non-adhesive section 264 that may be grasped bythe installer to remove the release sheets 142, 146. FIG. 21 is apartially exploded perspective view of the flashing assembly 106 shownin FIG. 20. FIG. 22 is a fully exploded perspective view of the flashingassembly 106 shown in FIGS. 21 and 22 and showing release sheets 142,146. The pull-tabs 262 allow for easy removal of the release sheets 142,146 from the first and second pads 118, 120 because the pull-tabs 262provide a location for the installer to grasp without contactingadhesive. Accordingly, the pull-tabs 262 allow the pads 118, 120 toinclude sticky materials with increased waterproof capabilities withoutthe installer's fingers sticking to the pads 118, 120. As a result, thepull-tabs 262 reduce the time and materials required to install thesystem and reduce the possibility of damage to the pads 118, 120 duringremoval of the release sheets 142, 146.

In another embodiment, the release sheet 142, 146 may be oversizedrelative to the respective attachment surfaces 124, 128 such that aportion of the release sheet is exposed for a user to grasp. Besidesallowing for easy release, the oversized release sheets 142, 146 maycover the edges 130 of the pad 118, 120 that can stick to other surfacesor to other flashing assemblies 106 when the flashing assemblies 106 arepackaged.

In another embodiment shown in FIGS. 23, 24, and 25, an oversizedrelease sheet 270 can include an adhesive strip 272 that sticks to thesecond and fourth release sheets 144, 148. Accordingly, the oversizedrelease sheet 270 can act as a pull-tab and an edge 130 protector. FIG.23 is a top view of the flashing assembly 106 with the oversized releasesheet 270. FIG. 24 is a partially exploded perspective view of theflashing assembly 106 shown in FIG. 23 with the second and fourthrelease sheets 142 and 146 attached to the pads 118 and 120,respectively. FIG. 25 is a fully exploded perspective view of theflashing assembly 106 shown FIG. 23.

The oversized release sheet 270 is rectangular and the adhesive strip272 extends across a width of the oversized release sheet 270. In otherembodiments, the system 100 may include any oversized release sheet 270that enables the system 100 to operate as described. For example, insome embodiments, the oversized release sheet 270 may be any suitableshape.

In another embodiment, an oversized release sheet 270 without theadhesive strip 272 is attached directly to the second and fourthattachment surfaces 124 and 128 of the first and second pads 118 and120. The oversized release sheets 270 prevent the edges 130 of the pads118 and 120 from sticking to the adjacent flashing assemblies 106. FIG.27 is a perspective view of the flashing assemblies 106 stacked forpackaging with maximum density. FIG. 26 is an exploded view of theflashing assemblies 106 shown in FIG. 27. In other embodiments, theflashing assembly 106 may include any release sheet 140, 142, 144, 146that enables the flashing assembly to function as described. The releasesheets 140, 142, 144, 146, and 270 allow the first and second pads 118,120 to be protected and prepared prior to installation and enable theuse of highly sticky materials that result in superior waterproofingperformance in comparison to known systems.

In reference to FIG. 6, the first pad 118 and the second pad 120 arecompressible. As used herein, the term “compressible” refers to amaterial that changes volume in response to changes in pressure.Suitably, the first pad 118 and the second pad 120 form awater-resistant seal when compressed. In this embodiment, the first pad118 is compressed between the flashing 108 and the surface 102 when theflashing assembly 106 is attached to the surface 102. The first pad 118conforms to imperfections, to textures, and around aggregate granules inthe roof surface 102 and adheres and seals to the surface 102. Thesecond pad 120 is compressed between the flashing 108 and the mount 104when the flashing 108 is connected to the mount 104. The second pad 120conforms to, fills, and adheres to imperfections and nonuniform featuresof the contact surface of the mount 104. In addition, the first pad 118is compliant and conforms to any gap between the surface 102 and theflashing 108 to maintain the water-resistant seal when the flashingassembly 106 experiences deflection caused by loads on the system 100.Also, the first pad 118 slightly raises the flashing 108 above thesurface 102 after installation. This aspect removes loading on theportion of the flashing 108 beyond the mount that can cause the flashing108 to warp which reduces the seal of the assembly. The removed loadingremoves the need for strengthening ribs within the flashing 108 oradditional and expensive stabilization pucks which increase the cost ofknown products. As a result, the flashing assembly 106 provides a lowercost and simpler product with a more repeatable and robustwater-resistant seal. In addition, the water-resistant seal ismaintained after an initial activation pressure is removed.

The first pad 118 and the second pad 120 may have any suitable shape andsize. For example, in this embodiment, the first pad 118 and the secondpad 120 are rectangular. In other embodiments, the first pad 118 and/orthe second pad 120 may be a square, a circle, a triangle, a trapezoid,an oval, a rectangle, a pentagon, a hexagon, or any other sidedmulti-sided shape. In addition, the first pad 118 and the second pad 120are flat or planar. The first pad 118 and the second pad 120 may eachhave a thickness in a range of about 0.01 inches (in.) to about 0.5 inor about 0.03 in. to about 0.25 in. or about 0.03 in. to about 0.125 in.or about 0.03 in. to about 0.08 in. In other embodiments, the pads 118,120 may be non-planar. For example, in some embodiments, the first pad118 and/or the second pad 120 may be conical. Also, in some embodiments,the shape of the first pad 118 and/or the second pad 120 may match theshape of the flashing 108 and/or the mount 104 to form a tortuous path,to provide a better mating surface, and/or to fill in gaps betweencomponents which inhibit water intrusion into the structure through theopening 116.

In this embodiment, a sealing washer 150 is positioned under a head ofthe fastener 110 as shown in FIG. 2. The sealing washer 150 provides aseal between the fastener 110 and the mount 104 to inhibit water ingressalong the fastener 110. The first pad 118 and the second pad 120 alsoseal around the fastener 110 and provide a second layer of protection.Known systems rely upon the sealing washer 150 as the critical or onlysealing component. In contrast, the first pad 118 and the second pad 120prevent water from entering the penetration in the surface 102 if waterflows past the sealing washer 150. Accordingly, the sealing washer 150is not the critical sealing component. In some embodiments, the sealingwasher 150 may be omitted.

To install the system 100, the flashing assembly 106 may be provided ata desired installation site in a pre-installation or firstconfiguration. In the first configuration, shown in FIG. 4, the firstpad 118 is attached to the lower surface 112 of the flashing 108 byremoving the first release sheet 140 from the first attachment surface122. The second pad 120 is attached to the upper surface 114 of theflashing 108 by removing the third release sheet 144 from the thirdattachment surface 126. An exploded view of the first configuration isshown in FIG. 5. To switch the flashing assembly 106 into aninstallation or second configuration, the second release sheet 142 andthe fourth release sheet 146 are removed from the second attachmentsurface 124 and the fourth attachment surface 128, respectively, asshown in FIG. 2. FIG. 3 is an exploded view of all components of thesystem 100. The flashing 108 is positioned along the surface 102 and thesecond attachment surface 124 is attached to the surface 102. Theflashing assembly 106 seals any corresponding pilot holes orpenetrations in the surface 102 when the flashing 108 is attached to thesurface 102. Accordingly, the flashing assembly 106 prevents wateringress through the penetrations after the flashing 108 is attached tothe surface 102 even if the installation of the system 100 is notimmediately completed. Accordingly, in contrast to known systems, extrasteps and components are not required to seal the penetrations if theinstallation is halted such as if the installers leave the installationsite due to rain.

To secure the mount 104 to the surface 102, the fourth attachmentsurface 128 is attached to the mount 104. The fastener 110 is positionedthrough an opening in the mount 104 and through the opening 116 in theflashing 108. The first pad 118 and the second pad 120 seal around thefastener 110 and form a water-resistant seal without requiring pressure.The fastener 110 is tightened and, as a result, the first pad 118 andthe second pad 120 are compressed. One or more PV modules may beattached to the mount 104. In other embodiments, the system 100 may beinstalled in any manner that enables the system 100 to operate asdescribed. For example, in some embodiments, the first pad 118 and/orthe second pad 120 may be attached to the flashing 108 simultaneously orafter positioning the flashing 108 on the surface 102. In otherembodiments, the first pad 118 and/or the second pad 120 do not includeadhesives and compression of the first pad 118 and/or the second pad 120provides the water-resistant seal without adhesive.

FIG. 7 is a perspective view of an embodiment of the system 100 showingthe flashing assembly 106 including notched flashing 202. The flashing202 is rectangular and includes four edges 204. At least one notch,broadly a location feature, 206 is positioned along at least one edge204 of the flashing 202. In the example, the flashing 202 includes threenotches 206. Each notch 206 is aligned with the opening (not shown inFIG. 4) of the flashing 202. The notches 206 allow an operator toposition the flashing assembly 106 in a target location on the surface102 (shown in FIG. 6). In addition, the notches 206 allow the operatorto align the mount 104 and/or the fastener 110 with the opening 116. Inother embodiments, the flashing 108 may include marks, projections,and/or any other suitable location features.

FIG. 8 is a perspective view of an embodiment of the flashing assembly106 and a mount 208. The mount 208 includes a first plate 210 and asecond plate 212. The first plate 210 and the second plate 212 arejoined along edges to form an L-shape. The first plate 210 includes anopening 214 sized to receive the fastener 110. The second plate 212includes a slot 216 sized to receive a fastener (not shown in FIG. 8)for securing a PV module and/or PV module support system to the mount208. An axis 218 extends along the joint between the first plate 210 andthe second plate 212. The opening 214 and the slot 216 are offset alongthe axis 218. The offset distance between the opening 214 and the slot216 may provide clearance for use of tools when the mount 208 and PVmodules are secured to the surface 102 (shown in FIG. 6). In otherembodiments, the mount 208 may include any openings that enable themount 208 to function as described.

The first pad 118 and the second pad 120 allow the flashing assembly 106to accommodate different mounts such as the mount 208 and the mount 104(shown in FIG. 1) because the pads 118, 120 can extend across and sealany openings in the flashing 108 that are provided to accommodate thedifferent mounts 104, 208. Moreover, the first pad 118 and the secondpad 120 may extend along only a portion of the mount 208 and may have asize different from the size of the mount 208 and/or the flashing 108.Accordingly, the first pad 118 and the second pad 120 are modular andmay be used with different flashing assemblies 106, flashings 108, andmounts 104.

FIG. 9 is a perspective view of an embodiment of the system 100including flashing 220 with a raised interface 222 for receiving themount 104. FIG. 10 is an exploded view of the system 100 including theflashing 220. FIG. 11 is a side view of the system 100 including theflashing 220. The raised interface 222 raises the opening 116 and themount 104 a distance from the planar surface of the flashing 220 andfrom the surface 102 (shown in FIG. 6). Accordingly, the raisedinterface 222 positions the opening 116 out of the path of water toinhibit water intrusion through the opening 116. In some embodiments,the raised interface 222 may be stamped into the flashing 220 and definea recess on the underside of the flashing 220. In other embodiments, theflashing 220 may include any raised interface 222 that enables theflashing to function as described. For example, in some embodiments, theflashing 220 and the raised interface 222 may be formed separately andattached together. In other embodiments, a block or support may bepositioned on or attached to the flashing 220 to space the mount 104from the flashing 220.

In the example, a first pad 224 is positioned on a lower surface 225(shown in FIG. 11) of the flashing 220 and extends into the recess ofthe raised interface 222. The first pad 224 has an increased thicknessin comparison to the first pad 118 (shown in FIG. 1). Specifically, thefirst pad 224 is sized to extend from the recess and be compressed whenthe flashing 220 is secured to the surface 102 (shown in FIG. 6). Thefirst pad 224 is rectangular and corresponds to a shape of the recess.In addition, the first pad 224 extends across the opening 116 when thefirst pad 224 is positioned in the recess. In other embodiments, theflashing assembly 106 may include any first pad 224 that enables theflashing assembly 106 to operate as described. For example, in someembodiments, the first pad 224 is sized to extend across the opening 116and does not necessarily fill or extend from the recess.

FIG. 12 is a perspective view of an embodiment of the system 100including the flashing 226 including a water deflection structure 228.The water deflection structure 228 extends partially around the mount104 and the opening 116 and is raised from the planar portion offlashing 226. Accordingly, the water deflection structure 228 inhibitswater from flowing towards the opening 116. The water deflectionstructure 228 defines a gap 230 that is downslope from the opening 116.Any water that is able travel upslope and through the gap 230 towardsthe opening 116 will be prevented from intruding into the structurethrough the opening 116 because the first pad 224 seals the opening 116.

With reference to FIGS. 13-15, the flashing assembly 106 may be usedwith a mount 232 having different configurations. For example, FIGS. 13and 14 show the flashing assembly 106 in use with a mount 232 in afirst, a “direct-to-deck attachment” configuration. FIG. 15 shows theflashing assembly 106 in use with the mount 232 in a second, “rafterattachment” configuration. The mount 232 includes middle openings 234and outer openings 236. The middle openings 234 are aligned along acenter axis of the mount 232 and receive the fasteners 110 when themount 232 is in the second configuration. The outer openings 236 arespaced along the periphery of the mount 104 and receive the fasteners110 when the mount 232 is in the first configuration. The mount includestwo middle openings 234 and four outer openings 236. The flashing 238includes openings 237. Each opening 237 is aligned with an opening 234,236 and receives the fastener 110 when the fastener 110 is positioned inthe respective opening 234, 236. In other embodiments, the mount 232 andthe flashing 238 may include any opening 234, 236, 237 that enables thesystem to function as described.

The first pad 118 and the second pad 120 allow the mount 104 to be usedin the first configuration and the second configuration because thefirst pad 118 and the second pad 120 extend across and seal each of theopenings 237. Accordingly, the openings 237 are sealed by the first pad118 and the second pad 120 when the fasteners 110 are positioned in theopenings 237 and when the fasteners 110 are not positioned in theopenings 237. Accordingly, the first pad 118 and the second pad 120allow the flashing assembly 106 to be modular and be used with differentmounts 104, 232 having different configurations. In contrast, knownsystems require different and/or additional components to accommodatedifferent configurations. For example, known systems require additionalcomponents to cover the openings in the flashing and/or in the mount forany unused fastener locations.

FIG. 16 is an exploded view of an embodiment of the system 100 includinga flashing 238 including a raised opening 240. An extension 241 extendsfrom the flashing 238 and defines the opening 240. The extension 241 issized to extend into the opening in the mount 104. The extension 241inhibits water intrusion through the opening 240. The first pad 118extends between the flashing 238 and the surface 102 (shown in FIG. 6)and provides a seal on the underside of the flashing 238 to the surface102. In addition, the fastener 110 extends through the opening 240,passes through the first pad 118, and is sealed when the fastener 110 issecured to the surface 102 (shown in FIG. 6). Accordingly, the first pad118 provides an additional and automatic double sealing (betweensurfaces 102 and flashing 238 and around the fastener 110) whichprovides a more reliable seal than products with only raised openings.In other embodiments, the flashing assembly 106 may include any flashing238 that enables the flashing assembly 106 to function as described.

FIG. 17 is an exploded view of an embodiment of the system 100 includinga pad 248 and a grommet 250. FIG. 18 is a perspective view of the lowersurface 112 of the flashing 108 shown in FIG. 17. The grommet 250 ispositioned at least partially in the opening 116 and seals around thefastener 110 when the fastener 110 is positioned in the opening 116. Thepad 248 is positioned on the lower surface 112 of the flashing 108. Thepad 248 defines an opening 252 that is aligned with the opening 116 inthe flashing 108. In addition, the opening 252 is larger than theopening 116 in the flashing 108. Accordingly, the pad 248 accommodatesthe grommet 250 in the opening 116. In addition, the pad 248 provides aseal between the flashing 108 and the surface 102 (shown in FIG. 6) anda raised platform to prevent flashing warpage when the fastener 110 istightened to a final position. This is an improvement over known systemsincluding grommets because the pad 248 provides an automatic andreliable sealing between the roofing surface 102 and the flashing 108and removes the need for additional field applied sealant between thesesurfaces which is required by known systems.

FIG. 19 is an exploded view of an embodiment of the system 100 includinga first pad 254 on a lower surface 112 of the flashing 108 and a secondpad 256 on the upper surface 114 of the flashing 108. The flashingassembly 106 also includes the grommet 250 positioned at least partiallyin the opening 116. The first pad 254 and the second pad 256 eachinclude an opening 258. The openings 258 are aligned with the opening116 in the flashing 108 and are sized to accommodate the grommet 250.The first pad 254 and the second pad 256 provide seals between the lowersurface 112 and the surface 102 (shown in FIG. 6) and between the uppersurface 114 and the mount 104. The grommet 250 provides a seal aroundthe fastener 110 when the grommet 250 and the fastener 110 arepositioned within the opening 116. In other embodiments, the flashingassembly 106 may include any seals that enable the flashing assembly 106to operate as described. For example, in some embodiments, at least oneof the first pad 254, the second pad 256, and the grommet 250 isomitted. This approach is an improvement over current systems includinggrommets because the flashing assembly 106 provides (1) a raisedplatform, (2) an automatic seal between the roofing surface 102 and theflashing 108, and (3) a robust water seal between the mount 104 and theflashing 108. Accordingly, the flashing assembly 106 provides anadditional water seal either to supplement the grommet or replace therequirement of the grommet to provide a seal at this interface.

As shown in FIG. 28, a u-shaped pad 274 can be used and applied to theflashing assembly 106. This provides a vast improvement to field appliedsealant and will work with many current technologies to create a fasterand cleaner installation and a more cost effective solution. Theu-shaped pad 274 extends around the opening 116 and inhibits waterintrusion into the structure through penetrations. The u-shaped pad 274defines a gap down flow of the opening 116 to allow any water to escape.In contrast, current systems include a field-applied sealant between thesurface 102 and the flashing 108 at the time of installation to preventwind driven rain or lateral water flow from traveling under the flashing108 and into the penetration in the surface. However, the systemsincluding field-applied sealant suffer from problems of requiringadditional materials and tools, the messy nature of field appliedsealants, and material compatibility. The u-shaped pad 274 allowsfield-applied sealants to be omitted and is compatible with a variety ofsystems.

Embodiments of the methods and systems described achieve superiorresults compared to prior methods and systems. For example, the systemsand methods described provide a complete water-resistant seal for aflashing assembly. In addition, the embodiments simplify theinstallation of PV modules on structures. More specifically, theembodiments reduce the labor, tools, and materials required for creatinga water-resistant seal on a surface at the mount locations of the PVmodules. Also, the systems and methods described may provide a morerobust and consistent seal at each mount location.

In addition, embodiments of the methods and systems described can beused with different mounts and different attachment configurationsbecause the pads seal all openings in the flashing. Accordingly, theembodiments reduce the cost to install flashing and reduce the risk offailures and leaks of the flashing. Also, the embodiments may reduce thetraining and/or experience required to properly install the flashing.

Embodiments of the described methods and systems are not limited to usewith photovoltaic assemblies. Rather, embodiments of the methods andsystems described may be used for flashing assemblies on any roofingsurface. For example, the methods and systems may be used forpenetrations in roofs such as vents and/or mechanical attachments thatextend through the roof.

When introducing elements of the present invention or the embodiment(s)thereof, the articles “a”, “an”, “the”, and “said” are intended to meanthat there are one or more of the elements. The terms “comprising”,“including”, and “having” are intended to be inclusive and mean thatthere may be additional elements other than the listed elements.

As various changes could be made in the above without departing from thescope of the invention, it is intended that all matter contained in theabove description and shown in the accompanying drawings shall beinterpreted as illustrative and not in a limiting sense.

What is claimed is:
 1. A system for flashing a mount of a photovoltaicassembly on a surface, the system comprising: a flashing including alower surface and an upper surface, the flashing defining an opening toreceive a fastener for securing the mount to the surface; a sealextending around the fastener when the fastener is positioned in theopening, wherein the seal provides a first barrier to inhibit waterintrusion through the opening; and a pad attached to one of the lowersurface and the upper surface, wherein the pad provides a second barrierto inhibit water intrusion through an interface of the flashing and thesurface.
 2. The system of claim 1, wherein the pad is attached to thelower surface and extends between the flashing and the surface when theflashing is attached to the surface.
 3. The system of claim 1, whereinthe pad is attached to the upper surface and extends between theflashing and the mount when the mount and the flashing are secured tothe surface.
 4. The system of claim 1, wherein the pad includes a firstattachment surface and a second attachment surface opposite the firstattachment surface.
 5. The system of claim 1, wherein the pad defines anopening that is aligned with the opening in the flashing.
 6. The systemof claim 5, wherein the seal is positioned in the opening in theflashing.
 7. The system of claim 1, wherein the fastener has a firstdiameter, the opening having a second diameter at least 20% greater thanthe first diameter.
 8. A system for flashing a mount of a photovoltaicassembly on a surface, the system comprising: a flashing including alower surface and an upper surface, the flashing defining an opening toreceive a fastener for securing the mount to the surface; and a paddisposed on one of the lower surface and the upper surface, wherein thepad is compressible and provides a seal to inhibit water intrusionthrough the opening.
 9. The system of claim 8, wherein the pad isattached to the lower surface and extends between the flashing and thesurface when the flashing is attached to the surface.
 10. The system ofclaim 8, wherein the pad is attached to the upper surface and extendsbetween the flashing and the mount when the mount and the flashing aresecured to the surface.
 11. The system of claim 8, wherein the padincludes a first attachment surface and a second attachment surfaceopposite the first attachment surface.
 12. The system of claim 8,wherein the pad defines an opening that is aligned with the opening inthe flashing.
 13. The system of claim 12, wherein a seal extends aroundthe fastener and is positioned in the opening in the flashing.
 14. Thesystem of claim 8, wherein the fastener has a first diameter, theopening having a second diameter at least 20% greater than the firstdiameter.
 15. A system for flashing a mount of a photovoltaic assemblyon a surface, the system comprising: a flashing including a lowersurface and an upper surface, the flashing defining an opening toreceive a fastener for securing the mount to the surface; and a padattached to the lower surface by adhesive, wherein the pad is U-shapedand provides a barrier to inhibit water intrusion between the surfaceand the lower surface of the flashing.
 16. The system of claim 15,wherein the pad defines a gap down flow of the opening.
 17. The systemof claim 15, wherein the pad includes a first attachment surface and asecond attachment surface opposite the first attachment surface.